INTRODUCTION TO

TRAIN 18
SILABHADRA DAS
PROFESSOR (TRAINSET)
IRIMEE
 TRAIN 18 CONCEPT

Concept of TRAIN 18 (VANDHE BHARATH EXPRESS) was Semi High

speed Multiple Unit Train set with quick acceleration and
contemporary passenger amenities.
 T-18
• 16 CAR DOUBLE HEADED TRAIN SET
• 24X16 = 384 METRES LENGTH
• 8 MOTOR CAR,
• 4 TRAILER CAR
• 2 Non DRIVING TRAILER CAR
• 2 DRIVING TRAILER CAR
• ALL COACHES ARE CHAIR CARS
• Out of 16 coaches , 2 coaches are Executive Class
 END BASIC UNIT

MIDDLE BASIC UNIT

DTC – Driving trailer coach

MC – Motor Coach
TC – Trailer Coach
NDTC – Non- Driving trailer coach
 Major technical features of Train 18
✓ 160 km/h speed . Test speed- 180 km/h
✓ Maximum Design Axle Load – 17 T (Actual–16.5 T)
✓ Starting Acceleration – 0.8 m/sec2
✓ Deceleration – 1 m/sec2
✓ 50 % Powering
✓ 4 Car Basic Unit. One Pantograph per each BU
✓ Wheel Mounted Brake Disc
✓ Bogie Control for Brake System as well as Traction
✓ All Propulsion equipments are underslung
✓ Bolsterless bogie
FEATURES OF TRAIN SET
• Indirect LED lights on Luggage Racks and AC Ducts
• Special air conditioning duct for silent and equal distribution of
conditioned Air.
•Provision of entertainment and mobile charging at every seat.
• Revolving seats at Executive class
• Wifi
• Gps based passenger information system
• All coaches having ONE onboard MINI PANTRY
Acceleration Vs Speed
Regenerative Effort vs Speed
per Motor Coach

Electric Locomotive – 280 to 300 KN

SEATING CAPACITY : 44
SEATING CAPACITY : 78
SEATING CAPACITY : 78
SEATING CAPACITY : 52
PASSENGER CAPACITY
TYPE OF PER NO.OF TOTAL
COACH COACH COACHES
DTC 44 2 88
NDTC/EC 52 2 104
MC 78 8 624
TC 78 4 312
TOTAL 1128
SHELL
SHELL DESIGN – Tubular structure more or less similar to LHB
shells
CONSULTANT FOR TRAIN 18: EC ENGINEERING POLAND,
➢ IRSM 41 corten steel underframe with centre sill design
➢ No trough floor
➢ 2mm thick SS cover sheets on underframe instead of
trough floor
➢ Side wall, Roof and End wall members of Ferritic
Stainless steel 2 mm,2.5 mm, 3 mm & 4 mm thick
➢ Roof Sheets: Austenitic Steel 1.25 mm & 1.7 mm thick
 UNDERFRAME
• Material : up to 10mm thickness IRS M 41
• Material: above 10 mm thickness EN 10025
• Sole bar section same as that of LHB (6mm)
• Head stock with lowered location of semi permanent coupler (
940 mm from Rail level)
 Design Validation
• Car body Design meets the requirements of EN 12663-1:2010+A1:2014 and DVS1612:2014.
• EN 12663-1:2010+A1:2014. Railway applications. Structural requirements of railway
vehicle bodies. Part 1: Locomotives and passenger rolling stock
• DVS 1612:2014. Design and endurance strength assessment of welded joints with steels
in rail vehicle construction
 BOGIE
BOLSTERLESS DESIGN

FULLY SUSPENDED TRACTION MOTOR

DISC BRAKE WITH BRAKE DISC ON WHEEL

AIR SPRING ON SECONDARY SUSPENSION

SPEED POTENTIAL CAN BE ENHANCED TO 200 Kmph

 Development of Bogies
Cannot be a motor
bogie

Existing Fiat 160 Km/h

As a TC bogie will
lead to non-
standardisation of
Bogie 160 Km/h Car body and Bogie

Motor as well as
New Development Trailer Bogies
Standardisation
WHEEL MOUNTED BRAKE DISC ON MOTOR AS WELL
AS TRAILER COACHES
BRAKE CALLIPERS

FULLY SUSPENDED
TRACTION MOTOR

WHEEL
MOUNTED
BRAKE DISC

FIAT BOGIE WITH AXLE

MOUNTED DISC BRAKES
Bolster Less Bogie with Fully Suspended
Traction Motors
✓ Reduced weight (Reduced Unsprung Mass)
✓ Better Ride Comfort
✓ Reduced number of Wearing Parts
✓ Greater Stability at higher speeds (Because of
Yaw dampers and rigidity of rubber items)
✓ Better performance on curves
Train-18 Bogie
Structural analysis of bogie frame according
to EN 13749:2011
 Bogies – Design Validation

• Dynamic Multi Body analysis shown stable behaviour upto 180 kmph
according to EN 14363 and RDSO’s Third Criteria Committee
• Simulation for the acceptance of running characteristics according to EN
14363:2016 - running behavior and stationary tests.
• The Simulation results matched the values of RDSO Trials
Structural analysis of bolted Joints -
VDI2230:2014
Structural analysis of monoblock wheel
according to EN 13979-1+A1 (2011)
 Furnishing
• World class furnishing , consultancy by Global players
• Entrance door with Retractable foot step (for first two rakes only)and Plug in -
plug out door- Knor Bremse
• Brake and controls – Knor Bremse and Faively
• Continuous Window which seems like a single window from out side – supply
UNIVERSAL ENGINEERS.
(FLATCH GLASS & SCHALBU FOR TRAIN 18)

• Panels and interiors by BFG and Hindustan Fibre Glass (HFG)

• IC DOORS by Prag Polymers
• Fully sealed gangway and exterior shroud by
Dellner, Avadh Rail Infra and Pioneer Fil-Med
Vacuum assisted Bio Toilets by Evac
Seats by STER (POLLAND)

Flooring - IMPORTED PVC BASED FLOKED FLOOR COVERING

by FLOTEX

Ducting by EC, HANSPAL and Universal Engineers

ELECTRICS,PROPULSION SYSTEM AND CONTROLS BY

MEDHA
FRP SKIN NOSE CONE

SUPPLY BY BFG
 PLUG DOOR

Automatic Single Leaf Plug

Door System with Retractable
Sliding FootStep

RETRACTABLE
FOOT STEP
Automatic Plug Doors with Sliding Foot Steps

✓ Provision of Sliding Step Required

shifting of door way to the end –
to avoid infringement with Bogie
✓ Door closing and opening switch is
on ALP side in driver cabin and
with guard
✓ Door closes after time delay of 3
seconds.
✓ Door opening causes traction
cutoff
Overview of door system
Overview of door system

Component overview Door control unit

• Pneumatic control unit

• Locking device

• Mechanical door
header gear isolation device

• Crew key switch

2 push buttons outside

2 push buttons inside • emergency egress

device

door leaf
• Cover of emergency
access device
Portal rubber • emergency
access device
Portal rubber
fixing profile
• lower door leaf guiding (roller
swing arm)
moveable step cover
Knorr-Bremse Group

• moveable step
 Brake System
EP Brake System with Latest Gen Electronic Platform

✓ Bogie level control of Brakes and Two Tier Redundancy of Mechanical and Electronic equipment
✓ Braking is a combination of Electro Pneumatic and Electro Dynamic braking (Blended braking)
✓ Electro dynamic brake preferred over electro pneumatic brake
✓ Maximum ED Brake force of 376 KN is possible. Balance braking force provided by EP brakes.
✓ Service Brake application on the basis of passenger load detected at secondary air spring level ( Load
corrected Braking)
✓ Wheel Slide Control and Jerk Control
✓ Quicker application and release (Lesser Brake distances)
✓ Oil free Compressors
 Brake System
Latest Generation Electronic Pneumatic Brake System

✓ For redundancy in WSP and BC pressure control.

✓ Latest electronic platform
✓ Quicker braking

✓ CENTRALIZED EP BRAKE SYSTEM WITH BOGIE

CONTROL

✓ Oil free Compressor

40
 Bio-Vacuum toilet System
✓ Unique Design
✓ Zero Discharge and Clean Toilets
TRAINSET INTERIOR FEATURES
 TRAINSET INTERIOR FEATURES
✓ Flooring.
✓ FRP-Interior panelling.
✓ Partitions with electrically operated touch free sliding doors.
✓ Endwall with Electrical inspection doors.
✓ Continuous window glass design with provision for emergency exit.
✓ AC-Ducting arrangement.
✓ Corrugated FRP roof panel design to improve aesthetics.
✓ Sunk in type Tip-up seat arrangement.
✓ On board infotainment system.
✓ Centralised coach monitoring system.
✓ Mini pantry and it’s storage area.
✓ Emergency alarm push buttons inside the compartment.
✓ Talk back unit inside and out side the compartment.
Properties of FRP panel
 Flooring

➢ Decoupling type floor board fixing arrangement similar to LHB coaches.

➢PVC based Flocked floor covering.
Partition with touch free automatic sliding door

➢ Aluminium honey comb or FRP foam with HPL sheet exterior doorway partitions.
➢ Electrically operated inter communication sliding door with emergency stop
provision.
➢ Concealed type infotainment partition displays.
➢ Provision for Passenger information system at top partition.
 Roof panelling with Air diffuser

LED Indirect Lighting

✓ Corrugated FRP roof panelling design.

✓ Wider AC Ducting for improvised Flow.
✓ Continuous air diffuser with Direct and
Indirect Lighting. AC Diffuser

LED Direct Lighting

 ✓ Interior Furnishing
✓ Design built up

LED Diffused Lighting

AC Diffuser

✓ Direct and Diffused Lighting LED Direct Lighting

Continuous
Windows

Initial Concept
Continuous window glass design with

Emergency window glass unite

➢Continuous window glass design contains sealed glass unite and pillar glass.
➢Provision of emergency window glass unite to use in emergency with glass
barker/hammer.
Emergency Passenger communication
system

➢Emergency talk back unit for passenger emergency communication.

AC ducting arrangement

➢Aluminium AC ducting arrangement with thermal and sound

insulation with return air provision.
 Air Conditioning
In Pantograph Coach

High Roof Area

Low Roof Area

✓ Low Head Room Below Pantograph

✓ Not feasible to extend the AC duct
and also the diffuser element will be
not sufficient to provide conditioned
Air to low roof area
Sleek Duct
For Low Roof

Main Duct

Transition Area

Low Roof Area

 CFD Analysis

Final result Noise – Free

Air-conditioning
 Concealed roller blind

Concealed Roller Blinds

➢ Concealed roller blind arrangement for all windows.

 Trainset-Safety features

Speaker Camera

Disaster
management light

➢ FRP roof panels with provision of camera, speaker, disaster management light and
fire detection system.
 Plug door pelmet with
entrance camera

Textured doors

Foot step Emergency

device
 Plug door
Electrical cubicle doors controllers
GANGWAYS
SEALED GANGWAYS

Relative movements. Non-articulated Vehicleconnections.

Construction type. Monobloc Gangway.

Fixation System. Bolted to Car body shell at one end.

Quick Latched at another end viaPlate.

Vertical throughway. 1954 mm

Horizontal throughway. 1150 mm
Curve radius at track R175m
Curve radius in depot R152.4m
Choice Of Gangway
✓ Simple Fully Sealed Gangway Vs Fully Sealed
Gangways with Inner and Exterior Fairings
✓ For contemporary exterior look as well as for free
passenger movement – Gangway with exterior
and interior fairings was chosen
✓ Mounting of exterior fairing required iterations of
changes in Inter Vehicular Electrical Couplers and
Roof HT Cable
 SEALED GANGWAYS
TRAIN18 Gangway Exploded View
Flexible Panel

Ceiling System
OuterBellows

Vehicle Mounting Plate

GACover

PlatformBarrier

LathingFaceplate

EdgeCover
Fixed Treadplate

Flexible Treadplate
COUPLERS
 Choice Of Coupler
• Tight Lock CBC couplers on Passenger Coaches –
where jerks are experienced
• Semi Permanent Couplers between Coaches
CBC Draft Gear with Semi Permanent Head • In search for Semi Permanent coupler to haul 24
Coaches, ICF zeroed on CBC draft gear with Semi
Permanent Head
• The Coupler is developed by M/s Dellner
• To Mount the Fully sealed gangway at the same
height of the coach floor (at 1320 mm from rail
level ), the coupler height has been reduced to
940mm from 1105 mm.
• This required modification of Coupler pocket on
the coach
TCMS – Train Control and
Management System
Major Function done by TCMS

✓ Interface with Driver Desk

✓ Pantograph Control
✓ VCB Control
✓ Traction Control
✓ Regenerative Brake Control and total brake calculation
✓ Brake Blending
✓ Interface with RMPU control
✓ Interface with Door control
✓ Interface with Brake control
✓ Compressor control
✓ Parking Brake control
✓ Light Control.
Major Function done by TCMS

✓ Rollback Detection
✓ Vigilance control
✓ Cruise Control
✓ Neutral Section Control
✓ Test Modes
✓ Settings through DDU
✓ Event Recording
✓ Centralized coach RMPU monitoring system
✓ All train level protection ( Ex: EOL, EBL, Cab Occupy).
TCMS – End Basic Unit
TCMS – Middle Basic Unit
ECN – Ethernet Consist Network
Utilized for communication within a Basic Unit

ETB – Ethernet Train Backbone (available in TC1 and MC2)

For inter basic unit communication

Train Line Signal – Communication network loop which originates from Front DTC and goes to rear end
DTC and returns to front DTC. It is connected CCU1, CC2, MCU, ACU.
It enables and indicates connectivity and continuity between Driver desk and all coaches of trainset

FGU – Frequency Generator Unit

If Train Line Signal fails, FGU gets turned on and ensures connectivity between DTC computers and coach
computers. In this case Vmax reduces to 100 Kmph. Special Rescue Drive mode.

CAN – Control Area Network

If Both FGU and Train line signal fails, CAN ensures communication
Rescue Drive Mode, Vmax reduces to 60 Kmph
INTER VEHICULAR CONNECTIONS
THANK YOU